钢轨打磨型面参数设计研究
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摘要
随着运量的不断提高以及对列车更高的速度要求,对铁路轨道结构的要求也随之不断提高,作为与车轮直接接触的钢轨则扮演了其最重要的角色,但重载、高速又使得钢轨出现了不可避免的各类磨耗伤损和病害,如何解决钢轨由于磨耗等引发的一系列伤损及病害问题成为整个铁路维护中的一个重要研究方向。
目前主要是通过对钢轨打磨、涂油、引进国外先进的打磨设备以及采用先进的钢轨生产工艺等手段来解决此类磨耗问题,结合成灌线实例,本文结合轮轨磨耗机理从钢轨型面设计方面对钢轨打磨技术进行研究,有目的性地对钢轨的型面参数进行控制,从而达到改善轮轨接触性能的目的。
本文通过对钢轨磨耗问题以及目前国内外钢轨打磨技术现状等进行了阐述,并对成都局管辖内的成灌线、成遂线以及宝成线的钢轨及车轮型面以及磨耗等各类伤损的调查分析,结合软件的计算分析,以成灌线为例对钢轨的型面进行了设计,提出了最优的钢轨轮廓面。针对目前的铁路现状,对钢轨型面设计理念进行了阐述,建立了一套较为合理的轮轨型面设计方法,并给出了轮轨型面设计的技术路线,为钢轨的打磨和铁路线路的维护提供了一定的理论支撑。
With the increasing railway traffic volume, the higher demand for train speed results in the increasing demand for railway track structure. The rail reacting with wheel directly plays an important role in maintaining the track safety, stability and durability. Due to the heavy haul and high-speed railway, different kinds of rail diseases like abrasion occur inevitability. How to solve the problem of rail diseases caused by abrasion is becoming an important research subject in the field of railway maintainance.
Currently, to lessen the rail abrasion depends on rail polishing, fat liquoring as well as the application of brought-in overseas advanced polishing equipments and rail productive technologies. In relation to the Chengdu-Dujiangyan passenger dedicated line, based on the mechanism of wheel-rail abrasion, the rail polishing technology is studied in terms of the rail profile design. And the parameters of the rail profile are purposefully controlled, thus improving the wheel-rail contact performance.
The status quo of rail abrasion and the rail polishing technologies at home and abroad was elaborated in the paper. Besides, the various diseases of rail and wheel profile with its abrasion included on the Chengdu-Dujiangyan railway line, Chengdu-Suining railway line and Baoji-Chengdu railway line managed by Chengdu Railway Bureau were investigated and analyzed. With the application of computer software, the rail profile on the Chengu-Dujiangyan railway line was designed to propose the optimum rail profile. Additionally, aiming at the current situation of railway, the concept of rail profile design was expounded. Furthermore, a set of relatively reasonable wheel-rail profile design method was established and the technical route of wheel-rail profile design was proposed, which, to some extent, provides the theoretical support for rail polishing and railway maintainance.
目前主要是通过对钢轨打磨、涂油、引进国外先进的打磨设备以及采用先进的钢轨生产工艺等手段来解决此类磨耗问题,结合成灌线实例,本文结合轮轨磨耗机理从钢轨型面设计方面对钢轨打磨技术进行研究,有目的性地对钢轨的型面参数进行控制,从而达到改善轮轨接触性能的目的。
本文通过对钢轨磨耗问题以及目前国内外钢轨打磨技术现状等进行了阐述,并对成都局管辖内的成灌线、成遂线以及宝成线的钢轨及车轮型面以及磨耗等各类伤损的调查分析,结合软件的计算分析,以成灌线为例对钢轨的型面进行了设计,提出了最优的钢轨轮廓面。针对目前的铁路现状,对钢轨型面设计理念进行了阐述,建立了一套较为合理的轮轨型面设计方法,并给出了轮轨型面设计的技术路线,为钢轨的打磨和铁路线路的维护提供了一定的理论支撑。
With the increasing railway traffic volume, the higher demand for train speed results in the increasing demand for railway track structure. The rail reacting with wheel directly plays an important role in maintaining the track safety, stability and durability. Due to the heavy haul and high-speed railway, different kinds of rail diseases like abrasion occur inevitability. How to solve the problem of rail diseases caused by abrasion is becoming an important research subject in the field of railway maintainance.
Currently, to lessen the rail abrasion depends on rail polishing, fat liquoring as well as the application of brought-in overseas advanced polishing equipments and rail productive technologies. In relation to the Chengdu-Dujiangyan passenger dedicated line, based on the mechanism of wheel-rail abrasion, the rail polishing technology is studied in terms of the rail profile design. And the parameters of the rail profile are purposefully controlled, thus improving the wheel-rail contact performance.
The status quo of rail abrasion and the rail polishing technologies at home and abroad was elaborated in the paper. Besides, the various diseases of rail and wheel profile with its abrasion included on the Chengdu-Dujiangyan railway line, Chengdu-Suining railway line and Baoji-Chengdu railway line managed by Chengdu Railway Bureau were investigated and analyzed. With the application of computer software, the rail profile on the Chengu-Dujiangyan railway line was designed to propose the optimum rail profile. Additionally, aiming at the current situation of railway, the concept of rail profile design was expounded. Furthermore, a set of relatively reasonable wheel-rail profile design method was established and the technical route of wheel-rail profile design was proposed, which, to some extent, provides the theoretical support for rail polishing and railway maintainance.
引文
[1]李成辉.轨道[M].成都：西南交通大学出版社,2005
[2]颜秉善,王其昌.钢轨力学与钢轨伤损[M].峨眉山市：西南交通大学出版社,1989
[3]董志洪.高技术铁路与钢轨[M].北京：冶金工业出版社,2003
[4]罗文俊,练松良,龚佩毅,杨文忠.钢轨焊接接头磨好的试验研究[J].铁道建筑,2008(11)：86-89
[5]温泽峰,金学松.非稳态荷载下轮轨滚动接触及其钢轨波磨研究[J].摩擦学学报,2007,27(3)：252-257
[6]BāhmerA,KlimpelT. Plastic deformation of corrugated rails:anumerical approach usingmaterial data of rail steel[J].Wear,2002,253(1-2):150-161
[7]齐笑丽,金祥.小半径曲线上股钢轨磨耗分析及防治[J].南钢科技与管理,2011(2)：54-56
[8]蒋万军.西南山区重载铁路钢轨磨耗探讨[J].科技创新导报,2011(15)：80-81
[9]E.Megel,M.Roney,P.Sroba,The blending of theory and practice in modern rail grinding[J].wear,2002(253):308-316
[10]Jochen Brandau.Wear reduction in light rail systems through asymmetrical railhead profiles[J].Boundary and Mixed Lubrication:Science and Application,2002:305-316
[11]国际重载协会.国际重载铁路最佳应用指南-轮轨关系[M].北京：中国铁道出版社,2009
[12]周亮节.钢轨打磨型面研究[D].成都：西南交通大学,2009
[13]张剑锋,高新平,王卫东.重载铁路钢轨打磨效果分析[J].铁道建筑,2009(4)：104-105
[14]王金虎.大秦线运量逐年递增情况下的钢轨伤损分析及对策[J].铁道建筑,2008(10)：98-100
[15]周宇,许玉德,曹亮.城市轨道交通钢轨表面在线整修技术的应用分析[J].城市轨道交通研究,2010：30-34
[16]徐爱民,高亮,袁昊.北京地铁轨道结构大修周期研究[J].铁道标准设计,,2009(2)：30-34
[17]金学松,杜星,郭俊,崔大宾.钢轨打磨技术研究进展[J].西南交通大学学报,2010,45(1)：1-10
[18]MARICH S.Rail grinding strategies adopted in Australia[J].Rail Engineering International,2005,9(4):4-6
[19]SHARMA S,Positive results from rail g rind ing in India[J].International Railway Journal,2004,XLIV(5):41
[20]JUDGE T.To grind,or not to grind?[J]. Railway Age,2002,203(11):33-36
[21]刘启跃,金学松.轮轨摩擦学[M].北京：中国铁道出版社,2004
[22]马培德.轮轨磨耗伤损机理分析[J].石家庄铁道学院学报,1995,8(1)：45-50
[23]愈展猷.轮轨磨耗机理与轮轨润滑[J].铁道机车车辆,2000(5)：11-14
[24]T.M.Beagley.Severe Wear of Rolling Sliding Contacts.WEAR.1976,36(7):317-335
[25]国际重载运输协会.重载铁路运输的最佳运营指南-轮轨界面问题[M].美国,2001
[26]A.V. Pan. Development of New Technologies for Current and Future Rail Production. Thesis Dr.Thech.Sci..(In Russian), Moscow, VNIIZhT, 1999,123
[27]K.Sawley,S.Clark. Engineering and Economic Implification of Hollow Worn Wheels on Wheel and Rail Asset Life and Fuel Consumption.Proceedings of IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow,1999,V1
[28]S.M.Zakharov, I.A.Zharov,I.Komarovsky. "Tribological Aspects of Rail/Wheel Interface." IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow, 1999,V1,221-228
[29]J.J.Kalker"Three Dimensional Elastic Bodies in Rolling Contact."Kluwer Academic Publishers,1990
[30]H.Tourney."Rail/Wheel Interaction from a Track and Vehicle Design Perspective."Proceedings of IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow, 1999,V1,41-57
[31]H.C.Inward,D.H.Stone,GJ.Moyar.A Thermal and Metallurgical Analysis of Martensite Formation and Tread palling During Wheel Skid.RTD-Vol.,Vol.5,Rail Tranportation, ASME,1992,105-116
[32]郭福安,张梅.客运专线钢轨打磨的思考[J].中国铁路,2008：53-54
[33]贺振中.国外钢轨打磨技术的应用与思考[J].中国铁路,2000(10)：38-40
[34]牛道安,李志强.提速线路钢轨打磨作业的探讨[J].铁道建筑,2006(8)：91-94
[35]雷晓燕.钢轨打磨原理及其应用[J].铁道工程学报,2000(1)：28-33
[36]Zarembski.A.M,On the benefits of rail maintenance grinding[R],AREA Bulletin.1988
[37]John Stanford,Peter Sroba,Eric Megel.Burlington Northern Santa Fe preventive gradual grinding initiative[R].AREMA,1999(9)
[38]Jochen Brandau.Wear reduction in light rail systems through asymmetrical railhead profiles[J].Boundary and Mixed Lubrication:Science and Application,2002:305-316
[39]POLACH O.Wheel profile design for target conicity and wide tread wear spreading[J].Wear,2010,267(1):1-18
[40]SHEVTSOV IY,MARKING VL,ESVELD C.Design of railway wheel profile taking into account rolling contact fatigue and wear[J].Wear,2008,265(9):1273-1282
[41]陈国庆.丰沙线曲线区段波磨钢轨打磨廓形优化的研究[D].成都：西南交通大学,1990
[42]刘启跃.减缓曲线钢轨侧磨的方法探讨[J].铁道建筑,1997(5)：28-30
[43]王文健,陈明韬,郭俊.高速铁路钢轨打磨技术及应用[J].西南交通大学学报,2007,42(5)：574-577
[44]郭俊,刘启跃,王文健.钢轨打磨对轮轨滚动接触斑行为影响研究[J].铁道建筑,2009(12)：92-94
[45]张剑,王玉艳,金学松,崔大宾.改善轮轨接触状态的车轮型面几何设计方法[J].交通运输工程学报,2011,11(1)：36-42
[46]任尊松.车辆动力学基础[M].北京：中国铁道出版社,2009
[47]柳拥军.高速轮轨接触几何学及高速轮轨几何型面优化的研究[D].北京：铁道部科学研究院,1999
[48]金学松.轮轨蠕滑理论及其试验研究[D].成都：西南交通大学,1999
[49]张军.基于有限元法的轮轨蠕滑理论研究[D].大连：大连理工大学,2003
[50]田蓓,王夏锹.非赫兹接触理论在货车轮轨接触应力分析中的应用[J].西南交通大学学报,1991(4)：88-95
[2]颜秉善,王其昌.钢轨力学与钢轨伤损[M].峨眉山市：西南交通大学出版社,1989
[3]董志洪.高技术铁路与钢轨[M].北京：冶金工业出版社,2003
[4]罗文俊,练松良,龚佩毅,杨文忠.钢轨焊接接头磨好的试验研究[J].铁道建筑,2008(11)：86-89
[5]温泽峰,金学松.非稳态荷载下轮轨滚动接触及其钢轨波磨研究[J].摩擦学学报,2007,27(3)：252-257
[6]BāhmerA,KlimpelT. Plastic deformation of corrugated rails:anumerical approach usingmaterial data of rail steel[J].Wear,2002,253(1-2):150-161
[7]齐笑丽,金祥.小半径曲线上股钢轨磨耗分析及防治[J].南钢科技与管理,2011(2)：54-56
[8]蒋万军.西南山区重载铁路钢轨磨耗探讨[J].科技创新导报,2011(15)：80-81
[9]E.Megel,M.Roney,P.Sroba,The blending of theory and practice in modern rail grinding[J].wear,2002(253):308-316
[10]Jochen Brandau.Wear reduction in light rail systems through asymmetrical railhead profiles[J].Boundary and Mixed Lubrication:Science and Application,2002:305-316
[11]国际重载协会.国际重载铁路最佳应用指南-轮轨关系[M].北京：中国铁道出版社,2009
[12]周亮节.钢轨打磨型面研究[D].成都：西南交通大学,2009
[13]张剑锋,高新平,王卫东.重载铁路钢轨打磨效果分析[J].铁道建筑,2009(4)：104-105
[14]王金虎.大秦线运量逐年递增情况下的钢轨伤损分析及对策[J].铁道建筑,2008(10)：98-100
[15]周宇,许玉德,曹亮.城市轨道交通钢轨表面在线整修技术的应用分析[J].城市轨道交通研究,2010：30-34
[16]徐爱民,高亮,袁昊.北京地铁轨道结构大修周期研究[J].铁道标准设计,,2009(2)：30-34
[17]金学松,杜星,郭俊,崔大宾.钢轨打磨技术研究进展[J].西南交通大学学报,2010,45(1)：1-10
[18]MARICH S.Rail grinding strategies adopted in Australia[J].Rail Engineering International,2005,9(4):4-6
[19]SHARMA S,Positive results from rail g rind ing in India[J].International Railway Journal,2004,XLIV(5):41
[20]JUDGE T.To grind,or not to grind?[J]. Railway Age,2002,203(11):33-36
[21]刘启跃,金学松.轮轨摩擦学[M].北京：中国铁道出版社,2004
[22]马培德.轮轨磨耗伤损机理分析[J].石家庄铁道学院学报,1995,8(1)：45-50
[23]愈展猷.轮轨磨耗机理与轮轨润滑[J].铁道机车车辆,2000(5)：11-14
[24]T.M.Beagley.Severe Wear of Rolling Sliding Contacts.WEAR.1976,36(7):317-335
[25]国际重载运输协会.重载铁路运输的最佳运营指南-轮轨界面问题[M].美国,2001
[26]A.V. Pan. Development of New Technologies for Current and Future Rail Production. Thesis Dr.Thech.Sci..(In Russian), Moscow, VNIIZhT, 1999,123
[27]K.Sawley,S.Clark. Engineering and Economic Implification of Hollow Worn Wheels on Wheel and Rail Asset Life and Fuel Consumption.Proceedings of IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow,1999,V1
[28]S.M.Zakharov, I.A.Zharov,I.Komarovsky. "Tribological Aspects of Rail/Wheel Interface." IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow, 1999,V1,221-228
[29]J.J.Kalker"Three Dimensional Elastic Bodies in Rolling Contact."Kluwer Academic Publishers,1990
[30]H.Tourney."Rail/Wheel Interaction from a Track and Vehicle Design Perspective."Proceedings of IHHA'99 STS-Conference on Wheel/Rail Interface, Moscow, 1999,V1,41-57
[31]H.C.Inward,D.H.Stone,GJ.Moyar.A Thermal and Metallurgical Analysis of Martensite Formation and Tread palling During Wheel Skid.RTD-Vol.,Vol.5,Rail Tranportation, ASME,1992,105-116
[32]郭福安,张梅.客运专线钢轨打磨的思考[J].中国铁路,2008：53-54
[33]贺振中.国外钢轨打磨技术的应用与思考[J].中国铁路,2000(10)：38-40
[34]牛道安,李志强.提速线路钢轨打磨作业的探讨[J].铁道建筑,2006(8)：91-94
[35]雷晓燕.钢轨打磨原理及其应用[J].铁道工程学报,2000(1)：28-33
[36]Zarembski.A.M,On the benefits of rail maintenance grinding[R],AREA Bulletin.1988
[37]John Stanford,Peter Sroba,Eric Megel.Burlington Northern Santa Fe preventive gradual grinding initiative[R].AREMA,1999(9)
[38]Jochen Brandau.Wear reduction in light rail systems through asymmetrical railhead profiles[J].Boundary and Mixed Lubrication:Science and Application,2002:305-316
[39]POLACH O.Wheel profile design for target conicity and wide tread wear spreading[J].Wear,2010,267(1):1-18
[40]SHEVTSOV IY,MARKING VL,ESVELD C.Design of railway wheel profile taking into account rolling contact fatigue and wear[J].Wear,2008,265(9):1273-1282
[41]陈国庆.丰沙线曲线区段波磨钢轨打磨廓形优化的研究[D].成都：西南交通大学,1990
[42]刘启跃.减缓曲线钢轨侧磨的方法探讨[J].铁道建筑,1997(5)：28-30
[43]王文健,陈明韬,郭俊.高速铁路钢轨打磨技术及应用[J].西南交通大学学报,2007,42(5)：574-577
[44]郭俊,刘启跃,王文健.钢轨打磨对轮轨滚动接触斑行为影响研究[J].铁道建筑,2009(12)：92-94
[45]张剑,王玉艳,金学松,崔大宾.改善轮轨接触状态的车轮型面几何设计方法[J].交通运输工程学报,2011,11(1)：36-42
[46]任尊松.车辆动力学基础[M].北京：中国铁道出版社,2009
[47]柳拥军.高速轮轨接触几何学及高速轮轨几何型面优化的研究[D].北京：铁道部科学研究院,1999
[48]金学松.轮轨蠕滑理论及其试验研究[D].成都：西南交通大学,1999
[49]张军.基于有限元法的轮轨蠕滑理论研究[D].大连：大连理工大学,2003
[50]田蓓,王夏锹.非赫兹接触理论在货车轮轨接触应力分析中的应用[J].西南交通大学学报,1991(4)：88-95